Wacker Neuson EW100 Mobile Excavator Service Manual – PDF DOWNLOAD

Description

Wacker Neuson EW100 Mobile Excavator Service Manual – PDF DOWNLOAD

FILE DETAILS:

Wacker Neuson EW100 Mobile Excavator Service Manual – PDF DOWNLOAD

Language : English
Pages : 374
Downloadable : Yes
File Type : PDF
Size: 20.8 MB

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DESCRIPTION:

Wacker Neuson EW100 Mobile Excavator Service Manual – PDF DOWNLOAD

Vehicle model E06-06
Edition 1.4
Language en
Article number 1000324385
From serial number WNCE0606TPAL00200

Operation:
1.1 Notices on this service manual:

This service manual contains important information on how to work safely, correctly and
economically with the vehicle. Therefore, it aims not only at new personnel, but it also
serves as a reference for experienced personnel. It helps to avoid hazardous situations
and reduce repair costs and downtimes.
Furthermore, the reliability and the service life of the machine will be increased.
Careful and prudent working is the best way to avoid accidents!
Operational safety and readiness of the machine do not only depend on your skill, but also
on maintenance and servicing of the machine. This is why regular maintenance and servicing
is absolutely necessary.
Use only original spare parts for repairs. This ensures operational safety and readiness of
your machine, and maintains its value.
Subject to modifications and printing errors.
Your Wacker Neuson Linz GmbH technical support will be happy to answer any further
questions regarding the machine or the service manual.

TABLE OF CONTENTS:

Wacker Neuson EW100 Mobile Excavator Service Manual – PDF DOWNLOAD

Operation
Notices on this service manual 1-2
Identification of warnings and dangers 1-3
Explanation of symbols and abbreviations 1-3
Abbreviations 1-4
Conversion table 1-5
Warranty and liability 1-6
Exemption from warranty and liability 1-6
Labels 1-7
Type labels 1-7
Machine overview 1-11
Engine compartment (overview) 1-12
Chassis overview 1-13
Battery master switch 1-14
Fire extinguisher 1-14
Technical data
Engine 2-2
Traveling drive/axles 2-3
Brakes 2-3
Tires 2-4
Steering system 2-4
Operating hydraulics 2-5
Travel speed 2-5
Electrical system 2-6
Electrical components 2-6
Fuses 2-6
Relays 2-7
Bulbs 2-8
Auxiliary hydraulics performance measurement 2-8
Payload/stability 2-8
Hose identification code 2-8
Tightening torques 2-9
Model-specific tightening torques 2-9
General tightening torques 2-9
Powertilt (option) 2-15
Coolant 2-15
Compound table 2-15
Noise emissions 2-15
Vibrations 2-15
Weight 2-16
Machine weight 2-16
Weight of attachments 2-16
Excavator forces 2-16
Ground clearance/ground pressure 2-16
Dimensions 2-17
EW100 triple articulation boom (overview) 2-17
EW100 one-piece boom (overview) 2-19
Kinematics 2-21
Measuring live ring tolerance 2-22
Maintenance
Information on maintenance 3-2
Responsibilities and prerequisites 3-2
Important safety instructions on maintenance 3-2
Table of Contents
I-2 SHB EW100 en – Edition 1 4 * EW100s10IVZ fm
Table of Contents
Special tools 3-3
Fluids and lubricants 3-3
Oil types for hydraulic system (depending on temperature) 3-4
Oil types for diesel engine (depending on temperature) 3-4
Important information regarding operation with biodegradable oil 3-5
Maintenance overview 3-6
Maintenance label 3-6
Maintenance plan 3-8
Maintenance accesses 3-14
Engine cover 3-14
Rocker cover 3-15
Tilting the cabin 3-16
Lowering the cabin 3-18
Main fuse box 3-19
Battery cover 3-20
Maintenance door 3-20
Partition wall maintenance accesses 3-20
Maintenance access to the live ring screw connection (from serial number
WNCE0606PPAL01135) 3-21
Interlocks 3-22
Fuel system 3-23
Important information regarding the fuel system 3-23
Diesel fuel specification 3-23
Refueling 3-23
Fuel prefilter with water separator 3-26
Emptying the water separator 3-26
Changing the fuel prefilter 3-27
Replacing the fuel filter 3-27
Bleeding the fuel system 3-29
Emptying the fuel tank 3-30
Engine lubrication system 3-31
Important information regarding the engine lubrication system 3-31
Checking the engine oil level 3-32
Adding engine oil 3-32
Changing engine oil 3-33
Replacing the engine-oil filter cartridge 3-34
Cooling system 3-36
Important information regarding the cooling system 3-36
Check the coolant level 3-37
Adding coolant 3-37
Draining coolant 3-38
Cleaning the radiator 3-39
Checking the oil level in the compressor 3-40
Adding refrigerant to the air conditioning system (option) 3-41
Air filter 3-42
Important information regarding the air filter 3-42
Air filter monitoring 3-42
Replacing the air filter 3-42
Checking the air intake 3-44
Replacing the cabin air filter 3-44
Washer system 3-45
Checking the fluid level and adding fluid 3-45
V-belt 3-46
Checking V-belt tension 3-46
Replacing the V-belt 3-47
Checking the V-belt of the air conditioning system (option) 3-48
Replacing the V-belt of the air conditioning system (option) 3-49
SHB EW100 en – Edition 1 4 * EW100s10IVZ fm I-3
Table of Contents
Replacing the crankcase breather filter 3-50
Gearboxes and axles 3-51
20 kph rear axle 3-51
40 kph rear axle (option) 3-52
Differential (rigid rear axle) 3-52
Differential (steered rear axle) 3-53
Front axle differential 3-54
Planetary drive of rigid rear axle 3-55
Planetary drive of steered rear axle 3-56
Front axle planetary drive 3-56
Traveling drive 3-57
Checking the oil level and adding oil 3-57
Changing oil 3-58
Pressure check 3-59
General 3-59
Prerequisites for pressure check 3-59
Measurement connections (overview) 3-60
Checking the pilot control pressure 3-60
Checking the LS pressure limiting valve 3-60
Setting the LS pressure limiting valve on the main valve block 3-61
Setting the secondary pressure limiting valve (PLV) 3-61
Checking the secondary pressure limiting valve on the gear motor 3-61
Checking the standby pressure (circulation pressure) 3-62
Checking the delta P pressure difference 3-62
Test report 3-63
Hydraulic system 3-65
Important information on the hydraulic system 3-65
Checking the hydraulic oil level 3-66
Adding hydraulic oil 3-67
Changing hydraulic oil 3-68
Changing the hydraulic oil filter element 3-69
Draining condensation water from the hydraulic oil reservoir 3-70
Replacing the boost-pressure filter 3-70
Replacing the pressure filter of the steering system 3-71
Checking the hydraulic system and hoses 3-71
Axle mounting 3-72
Front axle 3-72
Rear axle 3-72
Stop plate fastening of the oscillating axle 3-72
Lubrication work 3-73
Preparing lubrication 3-73
One-piece boom lubrication plan 3-74
Triple articulation boom (option) 3-76
Steering housing 3-79
Cardan shaft 3-79
Oscillating axle bearing mount 3-80
Lubricating the live ring (ball bearing) 3-81
Lubricating the teeth of the live ring 3-82
Control lever base lubrication points 3-83
Lubrication points for oscillating-axle cylinder 3-83
Powertilt with Easy Lock – operation in water 3-83
Maintenance of attachments 3-83
Tires 3-84
Inspection work 3-84
Tires 3-84
Electrical system 3-86
Important information regarding the electrical system 3-86
I-4 SHB EW100 en – Edition 1 4 * EW100s10IVZ fm
Table of Contents
Fuses and relays 3-86
Battery charge condition 3-87
Charging the battery 3-87
Replacing the battery 3-87
Cleaning and maintenance 3-88
Information on cleaning and maintenance 3-88
Use of solvents 3-88
Cleaning inside the cabin 3-89
Cleaning outside the machine 3-89
Cleaning the engine compartment 3-89
Cleaning the seat belt 3-90
Cleaning the machine in a saline environment 3-90
Threaded fittings and attachments 3-90
Resetting the maintenance meter 3-91
Engine
Perkins engine 854E-E34TAWF and 854F-E34TAWF 4-2
Engine overview 4-2
Wall-flow filter aftertreatment system 4-7
Engine block overview 4-8
Turbocharger 4-9
Clean the diesel particulate filter 4-9
Replacing the oxygen sensor 4-9
Check the water pump (visual check) 4-10
Engine malfunctions 4-11
Travel drive
Traveling drive overview 5-2
Traveling drive 20 kph – A6VM150/71 5-2
Traveling drive 30 kph/40 kph – A6VM80DA1 5-3
Traveling drive hydraulics diagram 5-4
Hydraulics diagram 20 kph 5-5
Hydraulics diagram 30 kph/40 kph 5-6
Traveling drive circuit (20 kph) 5-7
Traveling drive circuit (30 kph/40 kph) 5-8
Inching valve (omitted from serial no WNCE0606HPAL00884) 5-9
Towing the machine 5-10
Towing 5-11
Opening the “Travel” hydraulic circuit 5-11
Enabling the bypass function 5-12
Disabling the bypass function 5-13
Emergency unlocking of parking brake 5-14
Applying the parking brake again 5-16
Loading the vehicle 5-18
Driving onto transport vehicles 5-18
Brakes
Service brake 6-2
Parking brake 6-4
Steering system
Front axle steering 7-2
4 wheel steering (option) 7-3
Hydraulic system
Pump unit 8-2
Hydraulic pump 8-3
Connections 8-3
Components 8-4
Variable displacement pump design 8-5
SHB EW100 en – Edition 1 4 * EW100s10IVZ fm I-5
Table of Contents
Diagram 8-6
Hydraulic pump 8-7
Pump design 8-8
Hydraulic pump diagram 8-9
Mode of function of speed-sensitive control valve 8-10
Gear pump 8-11
Pilot oil supply unit 20 km/h (up to serial number WNCE0606JPAL00585) 8-12
Pilot oil supply unit 20 kph (diagram) 8-13
Pilot oil supply unit 20 km/h (up to serial number WNCE0606CPAL00586) 8-14
Pilot oil supply unit 20 kph (diagram) 8-15
Pilot oil supply unit 40 km/h (up to serial number WNCE0606JPAL00585) 8-16
Pilot oil supply unit 40 kph (diagram) 8-17
Pilot oil supply unit 40km/h (up to serial number WNCE0606CPAL00586) 8-18
Pilot oil supply unit 40 kph (diagram) 8-19
Main valve block RS12 (up to serial number WNCE0606JPAL00585) 8-20
Features 8-20
Connections 8-21
Diagram 8-22
Pressure limiting valve 8-23
Load Sensing/LUDV 8-24
Section RS12 8-25
Symbol 8-26
Segment RS12 8-27
Input segment RS12 8-28
Input segment diagram 8-29
Input segment 8-30
Main valve block RS12 (up to serial number WNCE0606CPAL00586) 8-31
Features 8-31
Connections 8-32
Diagram 8-33
Load Sensing/LUDV 8-34
Section RS12 8-35
Input segment RS12 8-36
Input segment diagram 8-37
Gear motor 8-38
Gear motor (from serial no WNCE0606PPAL01135) 8-39
Pilot valves 8-40
Joystick 8-40
Pilot valve of triple articulation boom 8-41
4-fold proportional valve 8-42
Stabilizer-blade valve 8-43
3rd control circuit (option) 8-44
Brake valve 8-45
Steering unit 8-46
Swivel joint 8-47
Other valves 8-48
Shuttle valve 8-48
Steering mode valve (option) 8-49
2-fold stabilizer leg valve (option) 8-50
4-fold stabilizer leg valve (option) 8-51
Auxiliary hydraulics performance measurement 8-52
Prerequisites for performance measurement 8-52
Performance diagram AUX I 8-53
Performance diagram AUX II 8-53
Electrical system
I-6 SHB EW100 en – Edition 1 4 * EW100s10IVZ fm
Table of Contents
Ohmic law (current, voltage, resistance); power 9-2
Measuring equipment, measuring methods 9-2
Cable color coding 9-3
Relays 9-4
Use, mode of function 9-4
Electrical system 9-4
Alternator 9-4
Starter 9-4
VANTAGE fuel-filling pump 9-5
Technical data 9-5
Components 9-6
System design 9-7
User interface 9-7
Functions 9-8
Status indicator 9-8
Access to board for electrical connections: 9-9
Main supply 9-9
Secondary supply with key 9-10
Level contact 9-11
Malfunctions 9-12
Maintenance 9-13
Engine wiring harness legend (up to serial number WNCE0606KPAL00505) 9-15
Engine wiring harness (up to serial number WNCE0606KPAL00505) 9-17
Engine wiring harness legend (up to serial number WNCE0606JPAL00506) 9-18
Engine wiring harness (up to serial number WNCE0606JPAL00506) 9-20
Engine wiring harness legend (up to serial number WNCE0606EPAL00692) 9-21
Engine wiring harness (up to serial number WNCE0606EPAL00692) 9-23
Chassis wiring harness legend 9-24
Chassis wiring harness 9-26
Chassis wiring harness (up to serial number WNCE0606EPAL00692) 9-27
Chassis wiring harness (up to serial number WNCE0606EPAL00692) 9-29
Switches wiring harness – version 1 (legend) 9-30
Switches wiring harness – version 1 9-33
Switches wiring harness – version 2 (legend) 9-34
Switches wiring harness – version 2 9-37
Switches wiring harness – version 3 and 4 (legend) 9-38
Switches wiring harness up to serial no WNCE0606VPAL01383 9-41
Switches wiring harness (from serial no WNCE0606APAL01384) 9-42
Travel gear wiring harness legend 9-43
Travel gear wiring harness 9-44
Boom light wiring harness 9-45
Rear lights wiring harness 9-46
Steering column wiring harness legend 9-47
Steering column wiring harness 9-48
Seat console wiring harness legend 9-49
Seat console wiring harness 9-51
Visco fan cable 9-52
Hydraulics diagram (legend) 10-2
Hydraulics diagram (up to serial number WNCE0606JPAL00585) 10-3
Hydraulics diagram (from serial number WNCE0606CPAL00586 to serial number
WNCE0606APAL00641) 10-4
Hydraulics diagram (serial no WNCE0606LPAL00642 to WNCE0606LPAL00883)
10-5
Hydraulics diagram (serial no WNCE0606HPAL00884 to WNCE0606TPAL01134)
SHB EW100 en – Edition 1 4 * EW100s10IVZ fm I-7
Table of Contents
10-6
Hydraulics diagram (from serial number WNCE0606PPAL01135) 10-7
Options hydraulics diagram (up to serial no WNCE0606LPAL01225) 10-8
Hydraulics diagram – options (from serial number WNCE0606HPAL01226) 10-9
Wiring diagram (legend) 10-10
Wiring diagram change directory 10-13
Wiring diagram 10-14
Options
Air conditioning 11-2
Specific safety instructions 11-2
Overview 11-3
Components 11-4
Filling up the air conditioning system 11-5
Malfunctions 11-7
Air-suspension seat 11-9
Connections 11-9
Long stick 11-9
Technical data 11-9
Service valve 11-10
Function 11-10
“Hose burst valve” safety feature 11-11
Safe load indicator pressure switch 11-12
Setting the pressure switch 11-13
Telematic 11-15
Connections 11-15
Functional check/diode 11-15
Diagnosis code list (SPN)

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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